Variable tooth saw blade

ABSTRACT

An apparatus for cutting materials and more specifically an improved saw blade includes a plurality of variable teeth thereon. The variable tooth saw blade cuts faster and smoother while reducing harmonic vibrations. Specifically, the teeth on the saw blade are grouped into sections with differing circumferential widths and differing spacing between the sections.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 10/845,284, filed May 13, 2004, which is acontinuation-in-part application of U.S. patent application Ser. No.10/391,425, filed Mar. 18, 2003, now U.S. Pat. No. 7,013,784, whichclaims priority from U.S. Provisional Patent Application Ser. No.60/365,999 filed Mar. 19, 2002; the disclosures of which areincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to rotary saw blades, and more particularlycircular saw blades for use on circular saws or the like. Specifically,the invention is directed to a variable tooth saw blade that cuts fasterand smoother while reducing harmonic vibrations.

2. Background Information

Circular saw blades are readily available for use in cutting wood andother materials using a portable, hand-held circular saw, or a fixedtable or radial saws, or other like saws. The saw blades are formed offlat, circular discs made of steel or other like metals. As is wellknown in the art, circular saw blades include a peripheral edge fromwhich a plurality of circumferentially-spaced teeth project radiallyoutwardly for cutting.

Users continually desire to purchase blades that allow for fastercutting without negative effects such as “burning” of the blade, dullingof the teeth, or jamming of the saw. The ability of the teeth toefficiently cut the material and thus maintain the blade speed iscritical. As a result, users continue to desire improved bladesproviding for faster and/or more efficient cutting.

Users also desire smooth cuts. Often the speed of a cut is inverselycorrelated to the smoothness of the cut, that is, the faster the usercuts, the rougher is the end cut, and vice versa. As a result, userscontinue to desire improved smoothness coupled with faster cutting.

Users further desire reduced noise. The high speed at which bladesrotate often causes high levels of harmonic vibration leading toexcessive noise, undesirable saw or saw blade vibration, and if thevibration is significant, a less than desirable cut. Users thus desire,and often government agencies require, blades providing for reducednoise and thus reduced harmonic vibration.

Consequently, there is a need for an improved saw that cuts faster andsmoother while also reducing noise and harmonic vibration.

SUMMARY OF THE INVENTION

The present invention provides a saw blade comprising a flat, circulardisc having a peripheral outer edge and a center hole; a plurality ofcircumferentially-spaced teeth each having a cutting edge and projectingradially outwardly from the peripheral outer edge; a first group of thecutting edges defining a first circumferential width between eachadjacent pair of the cutting edges in the first group; a second group ofthe cutting edges defining a second circumferential width between eachadjacent pair of the cutting edges in the second group; the secondcircumferential width differing from the first circumferential width;and a third group having at least two cutting edges defining a thirdcircumferential width as the distance between adjacent cutting edges inthe third group; the third circumferential width differing from thefirst and second circumferential widths.

The invention further provides a saw blade comprising a flat, circulardisc having a peripheral outer edge and a center hole, the disc beingdivided into a first half and a second half, each half being a copyexact of the other half positioned in a diametrically opposite manner; aplurality of circumferentially-spaced teeth each having a cutting edgeand projecting radially outwardly from the peripheral outer edge; afirst group in each half having five cutting edges including a firstcutting edge and a last cutting edge defining therebetween a first groupcircumferential width of approximately fifty-six degrees; a second groupin each half having three cutting edges including a first cutting edgeand a last cutting edge defining therebetween a second groupcircumferential width of approximately forty degrees; a third group ineach half having two cutting edges including a first cutting edge and alast cutting edge defining therebetween a third group circumferentialwidth of approximately twenty-five degrees; a first circumferentialspace being between the first and second groups in each half and havingan approximately fourteen-degree circumferential width; a secondcircumferential space being between the second and third groups in eachhalf and having an approximately twenty-degree circumferential width;and a third circumferential space being between the third group in eachhalf and the first group in the respective other half and having anapproximately twenty-five-degree circumferential width.

The invention further provides a saw blade comprising a flat, circulardisc having a peripheral outer edge and a center hole, the disc beingdivided into a first half and a second half, each half being a copyexact of the other half positioned in a diametrically opposite manner; aplurality of circumferentially-spaced teeth each having a cutting edgeand projecting radially outwardly from the peripheral outer edge; afirst group in each half having nine cutting edges including a firstcutting edge and a last cutting edge defining a first groupcircumferential width therebetween which is approximately thirty-sixdegrees; a second group in each half having seven cutting edgesincluding a first cutting edge and a last cutting edge defining a secondgroup circumferential width therebetween which is approximatelythirty-six degrees; a third group in each half having five cutting edgesincluding a first cutting edge and a last cutting edge defining a secondgroup circumferential width therebetween which is approximatelythirty-six degrees; a fourth group in each half having four cuttingedges defining a second group circumferential width therebetween whichis approximately forty-five degrees; a first circumferential space beingbetween the first and second groups in each half and having anapproximately four-and-a-half-degree circumferential width; a secondcircumferential space being between the second and third groups in eachhalf and having an approximately six-degree circumferential width; athird circumferential space being between the third and fourth groups ineach half and having an approximately nine-degree circumferential width;and a fourth circumferential space being between the fourth group ineach half and the first group in the respective other half and having anapproximately seven-and-a-half-degree circumferential width.

The invention further provides a saw blade comprising a flat, circulardisc having a peripheral outer edge and a center hole, the disc beingdivided into a first half and a second half, each half being a copyexact of the other half positioned in a diametrically opposite manner; aplurality of circumferentially-spaced teeth each having a cutting edgeand projecting radially outwardly from the peripheral outer edge; afirst group in each half having twelve cutting edges including a firstcutting edge and a last cutting edge defining a first groupcircumferential width therebetween which is approximatelythirty-eight-and-a-half degrees; a second group in each half havingeight cutting edges including a first cutting edge and a last cuttingedge defining a second group circumferential width therebetween which isapproximately thirty-two-and-a-half degrees; a third group in each halfhaving twelve cutting edges including a first cutting edge and a lastcutting edge defining a second group circumferential width therebetweenwhich is approximately sixty-six degrees; a fourth group in each halfhaving three cutting edges defining a second group circumferential widththerebetween which is approximately twenty-one-and-a-half degrees; afirst circumferential space being between the first and second groups ineach half and having an approximately three-and-a-half-degreecircumferential width; a second circumferential space being between thesecond and third groups in each half and having an approximatelyfour-and-a-half-degree circumferential width; a third circumferentialspace being between the third and fourth groups in each half and havingan approximately six-degree circumferential width; and a fourthcircumferential space being between the fourth group in each half andthe first group in the respective other half and having an approximatelyseven-and-a-half-degree circumferential width.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention, illustrative of the best modesin which the applicant has contemplated applying the principles, are setforth in the following description and are shown in the drawings and areparticularly and distinctly pointed out and set forth in the appendedclaims.

FIG. 1 is a side view of a first embodiment of the saw blade of thepresent invention;

FIG. 2 is the same side view of the first embodiment of the saw blade asin FIG. 1 with the sections clearly marked;

FIG. 3 is an enlarged view of a few teeth from the saw blade of thefirst embodiment in FIGS. 1-2;

FIG. 4 is a side view of a second embodiment of the saw blade of thepresent invention;

FIG. 5 is the same side view of the second embodiment of the saw bladeas in FIG. 4 with the sections clearly marked;

FIG. 6 is an enlarged view of a few teeth from the saw blade of thesecond embodiment in FIGS. 4-5;

FIG. 7 is a side view of a third embodiment of the saw blade of thepresent invention with the sections clearly marked;

FIG. 8 is an enlarged view of a few teeth from the saw blade of thethird embodiment in FIG. 7;

FIG. 9 is a side view of a fourth embodiment of the saw blade of thepresent invention with the sections clearly marked;

FIG. 10 is an enlarged view of a few teeth from the saw blade of thefourth embodiment in FIG. 9;

FIG. 11 is a side view of a fifth embodiment of the saw blade of thepresent invention with the sections clearly marked; and

FIG. 12 is an enlarged view of a few teeth from the saw blade of thefifth embodiment in FIG. 11.

Similar numbers refer to similar parts throughout the specification.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The improved saw blade of the present invention is shown in fiveembodiments in the Figures although other embodiments are contemplatedas is apparent to one of skill in the art. Specifically, the firstembodiment of the improved saw blade is indicated generally at 20 asshown in FIGS. 1-2; a second embodiment of the improved saw blade isindicated generally at 120 as shown in FIGS. 4-5; a third embodiment ofthe improved saw blade is indicated generally at 220 as shown in FIGS.7-8; a fourth embodiment of the improved saw blade is indicatedgenerally at 320 as shown in FIGS. 9-10; and a fifth embodiment of theimproved saw blade is indicated generally at 420 as shown in FIGS.11-12.

The first, second and third embodiments, respectively saw blades 20, 120and 220, are embodied as standard seven-and-one-quarter-inch diametersaw blades although each may be of any other diameter used orcontemplated by those of skill in the art. The fourth embodiment, sawblade 320, is embodied as a ten-inch diameter saw blade and the fifthembodiment, saw blade 320, is embodied as a twelve-inch diameter sawblade, although each may be of any other diameter used or contemplatedby those of skill in the art. The saw blade, whether embodied as blade20, 120, 220, 320 or 420, is a flat, circular disc 22, made of steel orother like metals, with a center arbor hole 24 as is well known in theart. The disc 22 includes a peripheral edge 30 with a plurality ofcircumferentially-spaced teeth projecting radially outwardly therefromfor cutting and generally referred to as 32. Each tooth 32 has a cuttingedge 44 and is more fully described below.

In accordance with one of the features of the invention, the blade isdivided into an even number of groups or sections, and in more detailblades 20 and 220 in respective first and third embodiments are eachdivided into six sections while blades 120, 320 and 420 in respectivesecond, fourth and fifth embodiments are each divided into eightsections. Each section along the peripheral edge has a matching or copyexact section diametrically opposite thereto such that a symmetry-likeline divides the blade into two halves of a repeating pattern.

In further accordance with one of the features of the invention, thesections in each half do not have the same number of teeth or teeth ofthe same size as the other sections. More particularly, there are adifferent number of cutting edges 44 in each section in each half andthe circumferential width between each adjacent cutting edges 44 withina given section is different than that of each other section in a givenhalf. Blade 420 of the fifth embodiment is a partial exception to thisrule regarding the differing number of teeth or cutting edges from groupto group. Specifically, blade 420 includes respectively within its foursections on one half of the blade twelve cutting edges, eight cuttingedges, twelve cutting edges and three cutting edges. Thus, while thenumber of cutting edges (and teeth) within each section changes betweenadjacent sections, the first and third sections have the same number ofcutting edges. However, the size of the teeth in each section of blade420 are different from those in each other section, as with the otherblades.

Preferably in accordance with another feature of the invention, the sizeof the teeth remains the same and/or decreases in each section from alargest size to a smallest size in the direction of cutting (or viceversa), while the number of teeth increases or remains the same in eachsection in the direction of cutting (or vice versa respectively). Moreparticularly, the circumferential width between each adjacent pair ofcutting edges 44 remains the same and/or decreases in each section fromlargest to smallest in the direction of cutting (or vice versa), whilethe number of cutting edges 44 increases or remains the same in eachsection in the direction of cutting (or vice versa respectively). Onceagain, blade 420 of the fifth embodiment is a partial exception to thispreferred rule. While the size of the teeth follow the rule, the numberof teeth does not, because, as described in the previous paragraph,blade 420 has a “twelve-eight-twelve-three” cutting edge pattern betweenrespective adjacent sections.

Each tooth 32 includes a tooth body 40 defined as a sloped face or land42 culminating in outwardly extending cutting edge 44. On the oppositeside of cutting edge 44 from land 42 is a notch 54 which communicateswith the land 42 of an adjacent tooth 32. Notch 54 thus separates thecutting edge 44 of one tooth 32 from the land 42 of an adjacent tooth32. More specifically, notch 54 includes a radial face 46 extendinginwardly toward hole 24 adjacent cutting edge 44 of one tooth 32 into abend 56 which communicates with land 42 of an adjacent tooth 32. Land 42may include an optional additional cutting or finishing edge 52 in themiddle thereof for reducing kick-back and providing smoother cuts,whereby such land 42 in the embodiment shown includes a first steeptapered section 48 and a second slightly tapered section 50 separated bythe additional cutting edge 52 although other configurations arecontemplated including only one tapered section of a constant taper or agradually changing taper. Specifically, land 42 may be any form of asurface behind tooth 32 that transitions into notch 54. Cutting edge 44may be a sharpened edge, or, as in the embodiments, an L-shaped seat 60in which an insert such as a carbide or diamond tip 62 is seated andsecured. The insert has a cutting face 64. Where an insert is used,cutting edge 64 becomes the cutting edge of a tooth 32 and thus the term“cutting edge” includes “cutting face” in that scenario.

Generally, it is preferred that tooth 32 include a cutting edge 52, asshown in FIG. 8, which helps remove saw dust from blade 220, 320 or 420to enhance the cutting effect of cutting edge 44 or cutting edge 64.Alternately, cutting edge 52 may be an anti-kickback hump, as shown inFIG. 10, which limits the rate of cutting to prevent the saw blade fromkicking back and causing injury. Smaller-size teeth are simply too smallto practically accommodate a cutting edge 52, as seen with the teeth insection 380 on blade 320 and in section 480 on blade 420.

In accordance with yet another feature of the invention, the hook angleα of each tooth is most preferably between 15° (fifteen degrees) and 25°(twenty-five degrees). The hook angle α is specifically the anglebetween the tangent to the cutting face 44 and a radius line throughhole 24.

In accordance with yet one more feature of the invention, it has beendiscovered that alternating the number of teeth or cutting edges inadjacent sections from odd to even provides additional benefitsincluding noise reduction. Blade 120 of the second embodiment is theonly blade of those described herein adhering to this pattern. However,it has also been found that noise and vibrations are reduced with bladesincluding at least one section having an even number of cutting edgesand at least one section having an odd number of cutting edges.

In more detail as to the first embodiment of the blade referred to as20, teeth 32 are arranged in a unique eighteen-tooth design that isdivided into two copy exact sections, namely a first side 70A and asecond side 70B divided by axis 72. Since the blade as shown in FIGS.1-2 has a right and left copy exact side (sides 70A and 70Brespectively), only the right side will be described below (except wherenecessary to refer to the other or left side where transitions occur).The first side 70A includes nine teeth, namely teeth 32A, 32B, 32C, 32D,32E, 32F, 32G, 32H, and 321 separated by voids 54.

In accordance with another feature of the invention, the nine teeth 32A,32B, 32C, 32D, 32E, 32F, 32G, 32H, and 321 of each side 70A and 70B arenot identical in size and spacing. Specifically in the embodiment shown,first side 70A is divided into three sections 80, 82 and 84 (and thusthe saw blade 20 has six sections over sides 70A and 70B) of varyingcircumferential distance with differing number of teeth and size ofteeth in each.

Section 80 includes cutting edges 44 of five teeth 32, namely teeth 32A,32B, 32C, 32D, and 32E. Section 80 also includes the trailing componentsof four teeth 32, namely teeth 32B, 32C, 32D, and 32E, so that thosefour teeth are fully within section 80. These trailing componentsinclude land 42 having tapered sections 48 and 50, and optionaladditional cutting edge 52. Thereafter, section 82 includes cuttingedges 44 of three teeth, namely teeth 32F, 32G and 32H. Section 82 alsoincludes the trailing components of two teeth, namely teeth 32G and 32H,so that those two teeth are fully within section 82. Further thereafter,section 84 includes cutting edge 44 of one tooth, namely tooth 321,along with its trailing components, so that tooth 321 is fully withinsection 84.

Each of sections 80, 82 and 84 is specifically measured as thecircumferential width from the first cutting edge 44 of a section to thelast cutting edge 44 in the same section except where a section has onlyone cutting edge 44 and thus its circumferential width is defined fromthe cutting edge 44 of the last tooth 32 of the previous section to theonly cutting edge 44 in the section.

Specifically, section 80 is the circumferential width from the cuttingedge 44 of the first tooth 32A of the section 80 to the cutting edge 44of the last tooth 32E in the same section 80, which is defined as angleβ. Section 82 is the circumferential width from the cutting edge 44 ofthe first tooth 32F of the section 82 to the cutting edge 44 of the lasttooth 32H in the same section 82, which is defined as angle χ. Section84 with only one tooth is the circumferential width from the cuttingedge 44 of the last tooth 32H of the previous section 82 to the onlycutting edge 44 of the only tooth 321 in the section 84, which isdefined as angle δ. The previous section for the first section is thelast section, which would mean the last section of the other side wherethe blade has two copy exact sides, or simply the last section in thecase where the sections span the entire circumference of the blade. Forexample, the section previous to section 80 of side 70A is section 84 ofside 70B.

In between each of the sections are transitions or circumferentialspaces 90, 92, and 94. Specifically, transition 90 is the space betweensections 80 and 82, transition 92 is the space between sections 82 and84 but since the section 84 has only one tooth then no transition existsas section 84 and transition 92 have the same definition, and transition94 is the space between sections 84 and 80 of the next side (the leftside). This space is defined as the circumferential width from thecutting edge 44 of the last tooth of a section to the cutting edge 44 ofthe first tooth in the next section. Specifically, transition 90 is thecircumferential width from the cutting edge 44 of the tooth 32E ofsection 80 to the cutting edge 44 of the tooth 32F in the next section82, which is defined as angle ε. Transition 92 does not exist due to theone-tooth nature of section 84. Transition 94 is the circumferentialwidth from the cutting edge 44 of the tooth 321 of section 84 to thecutting edge 44 of the tooth 32A in the next section 80 (which is on theother side or left side in this case), which is defined as angle φ.

In accordance with one of the features of the invention, the sectionangle β is 60°, the section angle χ is 40°, the section angle δ is 36°,the transition angle ε is 20°, and the transition angle φ is 24°. Theeffect is a design where section 80 has cutting edges 44 for five teeth,section 82 has cutting edges 44 for three teeth, and section 84 hascutting edges for one tooth, with uneven transitions between sections 80and 82, and between 84 and 80 of the other side (the left side).Although it is noted above that no transition 92 exists between sections82 and 84 because the definition of transition 92 is the same as section84, nonetheless, it is also seen that what might be considered astransition 92 also differs from the either of transitions 90 and 94.

In more detail as to the second embodiment of the blade referred to as120, teeth 32 are arranged in a unique thirty-six tooth design that isdivided into two copy exact sections, namely a first side 170A and asecond side 170B by axis 172. Since the blade as shown in FIGS. 4-5 hasa right and left copy exact side (sides 170A and 170B respectively),only the right side will be described below (except where necessary torefer to the left side). The first side 170A includes eighteen teeth,namely teeth 132A, 132B, 132C, 132D, 132E, 132F, 132G, 132H, 132I, 132J,132K, 132L, 132M, 132N, 132O, 132P, 132Q, and 132R.

As with the first embodiment and in accordance with one of the featuresof the invention, the eighteen teeth 132A, 132B, 132C, 132D, 132E, 132F,132G, 132H, 132I, 132J, 132K, 132L, 132M, 132N, 132O, 132P, 132Q, and132R of each side 170A and 170B are not identical in size and spacing.Specifically in the embodiment shown, first side 170A is divided intofour sections 180, 182, 184 and 186 (and thus saw blade 120 has eightsections) of varying circumferential distance with differing number ofteeth and size of teeth in each. Section 180 includes cutting edges 44of seven teeth, namely teeth 132A, 132B, 132C, 132D, 132E, 132F, and132G. Section 180 also includes the trailing components of six teeth,namely teeth 132B, 132C, 132D, 132E, 132F and 132G, so that those sixteeth are fully within section 180. As noted above, the trailingcomponents include land 42 including tapered sections 48 and 50, andoptional additional cutting edge 52. Thereafter, section 182 includescutting edges 44 of six teeth, namely teeth 132H, 132I, 132J, 132K, 132Land 132M. Section 182 also includes the trailing components of fiveteeth, namely teeth 132I, 132J, 132K, 132L and 132M, so that those fiveteeth are fully within section 182. Further thereafter, section 184includes cutting edges 44 of three teeth, namely teeth 132N, 132O and132P. Section 184 also includes the trailing components of two teeth,namely teeth 132O and 132P, so that those two teeth are fully withinsection 184. Finally thereafter, section 186 includes cutting edges 44of two teeth, namely teeth 132Q and 132R, along with the trailingcomponents of tooth 132R, so that tooth 132R is fully within section186.

In the same manner as described above with reference to the firstembodiment, each section is specifically measured as the circumferentialwidth from the cutting edge 44 of the first tooth of a section to thecutting edge 44 of the last tooth in the same section except where asection has only one tooth 132 and thus its circumferential width isdefined from the cutting edge 44 of the last tooth 132 of the previoussection to the cutting edge 44 of the only tooth 132 in the section.Specifically, section 180 is the circumferential width from the cuttingedge 44 of the first tooth 132A of the section 180 to the cutting edge44 of the last tooth 132G in the same section 180, which is defined asangle γ. Section 182 is the circumferential width from the cutting edge44 of the first tooth 132H of the section 182 to the cutting edge 44 ofthe last tooth 132M in the same section 182, which is defined as angleη. Section 184 is the circumferential width from the cutting edge 44 ofthe first tooth 132N of the section 184 to the cutting edge 44 of thelast tooth 132P in the same section 184, which is defined as angle φ.Section 186 is the circumferential width from the cutting edge 44 of thefirst tooth 132Q of the section 186 to the cutting edge 44 of the lasttooth 132R in the same section 186, which is defined as angle κ.

In between each of the sections are transitions or circumferentialspaces 190, 192, 194 and 196. Specifically, transition 190 is the spacebetween sections 180 and 182, transition 192 is the space betweensections 182 and 184, transition 194 is the space between sections 184and 186, and transition 196 is the space between sections 186 and 180 ofthe next side (the left side). This space is defined as thecircumferential width from the cutting edge 44 of the last tooth of asection to cutting edge 44 of the first tooth in the next section.Specifically, transition 190 is the circumferential width from cuttingedge 44 of tooth 132G of section 180 to cutting edge 44 of tooth 132H inthe next section 182, which is defined as angle λ. Transition 192 is thecircumferential width from cutting edge 44 of tooth 132M of section 182to cutting edge 44 of tooth 132N in the next section 184, which isdefined as angle μ. Transition 194 is the circumferential width fromcutting edge 44 of tooth 132P of section 184 to cutting edge 44 of tooth132Q in the next section 186, which is defined as angle θ. Transition196 is the circumferential width from cutting edge 44 of tooth 132R ofsection 186 to cutting edge 44 of tooth 132A in the next section 180(which is on the other side or left side in this case), which is definedas angle α.

In accordance with one of the features of the invention, thecircumferential width or section angle γ is 36.015°, the section angle ηis 44.985°, the section angle φ is 30.015°, the section angle κ is 20°,the transition angle λ is 9°, the transition angle μ is 9.985°, thetransition angle α is 10°, and the transition angle σ is 20°.

In more detail as to the third embodiment of the blade referred to as220, teeth 32 are arranged in a unique twenty-tooth design that isdivided into two copy exact sections, namely a first side 270A and asecond side 270B divided by axis 272. Since the blade as shown in FIGS.7-8 has a right and left copy exact side (sides 270A and 270Brespectively), only the right side will be described below (except wherenecessary to refer to the other or left side where transitions occur).The first side 270A includes ten teeth, namely teeth 232A, 232B, 232C,232D, 232E, 232F, 232G, 232H, 232I and 232J separated by voids 54.

In accordance with another feature of the invention, the ten teeth 232A,232B, 232C, 232D, 232E, 232F, 232G, 232H, 232I and 232J of each side270A and 270B are not identical in size and spacing. Specifically in theembodiment shown, first side 270A is divided into three sections 280,282 and 284 (and thus the saw blade 220 has six sections over sides 270Aand 270B) of varying circumferential distance with differing number ofteeth and size of teeth in each.

Section 280 includes cutting edges 44 of five teeth 32, namely teeth232A, 232B, 232C, 232D, and 232E. Section 280 also includes the trailingcomponents of four teeth 32, namely teeth 232B, 232C, 232D, and 232E, sothat those four teeth are fully within section 280. These trailingcomponents include land 42 having tapered sections 48 and 50, andoptional additional cutting edge 52. Thereafter, section 282 includescutting edges 44 of three teeth, namely teeth 232F, 232G and 232H.Section 282 also includes the trailing components of two teeth, namelyteeth 232G and 232H, so that those two teeth are fully within section282. Further thereafter, section 284 includes cutting edge 44 of twoteeth, namely teeth 232I and 232J, along with the trailing components oftooth 232J so that tooth 232J is fully within section 284.

Each of sections 280, 282 and 284 is specifically measured as thecircumferential width from the first cutting edge 44 of a section to thelast cutting edge 44 in the same section. Specifically, section 280 isthe circumferential width from the first cutting edge 44 of tooth 232Aof section 280 to the last cutting edge 44 of tooth 232E in the samesection 280, which is defined as angle B. Section 282 is thecircumferential width from the first cutting edge 44 of tooth 232F ofsection 282 to the last cutting edge 44 of tooth 232H in the samesection 282, which is defined as angle D. Section 284 is thecircumferential width from the first cutting edge 44 of tooth 232I ofsection 284 to the last cutting edge 44 of tooth 232J in the samesection 284, which is defined as angle F.

In between each of the sections are transitions or circumferentialspaces 290, 292, and 294. Specifically, transition 290 is the spacebetween sections 280 and 282, transition 292 is the space betweensections 282 and 284, and transition 294 is the space between sections284 and 280 of the next side (the left side). This space is defined asthe circumferential width from the last cutting edge 44 of a section tothe first cutting edge 44 in the next section. Specifically, transition290 is the circumferential width from the last cutting edge 44 of tooth232E of section 280 to the first cutting edge 44 of tooth 232F in thenext section 282, which is defined as angle C. Transition 292 is thecircumferential width from the last cutting edge 44 of tooth 232H ofsection 282 to the first cutting edge 44 of tooth 232I in the nextsection 284, which is defined as angle E. Transition 294 is thecircumferential width from the last cutting edge 44 of the tooth 232J ofsection 284 to the first cutting edge 44 of tooth 232A in the nextsection 280 (which is on the other side or left side in this case),which is defined as angle A.

In accordance with one of the features of the invention, the sectionangle B falls in a range of 54° to 58°, the section angle D falls in arange of 38° to 42°, the section angle F falls in a range of 23° to 27°,the transition angle C falls in a range of 12° to 16°, the transitionangle E falls in a range of 18° to 22°, and the transition angle A fallsin a range of 23° to 27°. More preferably, the section angle B isapproximately 56°, the section angle D is approximately 40°, the sectionangle F is approximately 25°, the transition angle C is approximately14°, the transition angle E is approximately 20°, and the transitionangle A is approximately 25°. Most preferably, section angle B is56.000°, the section angle D is 40.000°, the section angle F is 25.000°,the transition angle C is 14.000°, the transition angle E is 20.000°,and the transition angle A is 25.000°. The effect is a design wheresection 280 has cutting edges 44 for five teeth, section 282 has cuttingedges 44 for three teeth, and section 284 has cutting edges for twoteeth, with uneven transitions between sections 280 and 282, between 282and 284, and between 284 and 280 of the other side (the left side).

In more detail as to the fourth embodiment of the blade referred to as320, teeth 32 are arranged in a unique fifty-tooth design that isdivided into two copy exact sections, namely a first side 370A and asecond side 370B by axis 372. Since the blade as shown in FIGS. 9-10 hasa right and left copy exact side (sides 370A and 370B respectively),only the right side will be described below (except where necessary torefer to the left side). The first side 370A includes twenty-five teeth,namely teeth 332A, 332B, 332C, 332D, 332E, 332F, 332G, 332H, 332I, 332J,332K, 332L, 332M, 332N, 332O, 332P, 332Q, 332R, 332S, 332T, 332U, 332V,332W, 332X, and 332Y.

As with the previous embodiments and in accordance with one of thefeatures of the invention, the twenty-five teeth 332A, 332B, 332C, 332D,332E, 332F, 332G, 332H, 332I, 332J, 332K, 332L, 332M, 332N, 332O, 332P,332Q, 332R, 332S, 332T, 332U, 332V, 332W, 332X, and 332Y of each side370A and 370B are not identical in size and spacing. Specifically in theembodiment shown, first side 370A is divided into four sections 380,382, 384 and 386 (and thus saw blade 320 has eight sections) of varyingcircumferential distance with differing number of teeth and size ofteeth in each. Section 380 includes cutting edges 44 of nine teeth,namely teeth 332A, 332B, 332C, 332D, 332E, 332F, 332G, 332H and 332I.Section 380 also includes the trailing components of eight teeth, namelyteeth 332B, 332C, 332D, 332E, 332F, 332G, 332H and 332I, so that thoseeight teeth are fully within section 380. As noted above, the trailingcomponents include land 42 including tapered sections 48 and 50, andoptional additional cutting edge 52. Thereafter, section 382 includescutting edges 44 of seven teeth, namely teeth 332J, 332K, 332L, 332M,332N, 332O and 332P. Section 382 also includes the trailing componentsof six teeth, namely teeth 332K, 332L, 332M, 332N, 332O and 332P, sothat those six teeth are fully within section 382. Further thereafter,section 384 includes cutting edges 44 of five teeth, namely teeth 332Q,332R, 332S, 332T and 332U. Section 384 also includes the trailingcomponents of four teeth, namely teeth 332R, 332S, 332T and 332U, sothat those four teeth are fully within section 384. Finally thereafter,section 386 includes cutting edges 44 of four teeth, namely teeth 332V,332W, 332X and 332Y. Section 386 also includes the trailing componentsof three teeth, namely teeth 332W, 332X and 332Y, so that those threeteeth are fully within section 386.

As with the previous embodiments, each of sections 380, 382, 384 and 386is specifically measured as the circumferential width from the firstcutting edge 44 of a section to the last cutting edge 44 in the samesection. Specifically, section 380 is the circumferential width from thefirst cutting edge 44 of tooth 332A of section 380 to the last cuttingedge 44 of tooth 332I in the same section 380, which is defined as angleH. Section 382 is the circumferential width from the first cutting edge44 of tooth 332J of section 382 to the last cutting edge 44 of tooth332P in the same section 382, which is defined as angle J. Section 384is the circumferential width from the first cutting edge 44 of tooth332Q of section 384 to the last cutting edge 44 of tooth 332U in thesame section 384, which is defined as angle L. Section 386 is thecircumferential width from the first cutting edge 44 of tooth 332V ofsection 386 to the last cutting edge 44 of tooth 332Y in the samesection 386, which is defined as angle N.

In between each of the sections are transitions or circumferentialspaces 390, 392, 394 and 396. Specifically, transition 390 is the spacebetween sections 380 and 382, transition 392 is the space betweensections 382 and 384, transition 394 is the space between sections 384and 386, and transition 396 is the space between sections 386 and 380 ofthe next side (the left side). This space is defined as thecircumferential width from the last cutting edge 44 of a section to thefirst cutting edge 44 in the next section. Specifically, transition 390is the circumferential width from the last cutting edge 44 of tooth 332Iof section 380 to the first cutting edge 44 of tooth 332J in the nextsection 382, which is defined as angle I. Transition 392 is thecircumferential width from the last cutting edge 44 of tooth 332P ofsection 382 to the first cutting edge 44 of tooth 332Q in the nextsection 384, which is defined as angle K. Transition 394 is thecircumferential width from the last cutting edge 44 of the tooth 332U ofsection 384 to the first cutting edge 44 of tooth 332V in the nextsection 386, which is defined as angle M. Transition 396 is thecircumferential width from the last cutting edge 44 of the tooth 332Y ofsection 386 to the first cutting edge 44 of tooth 332A in the nextsection 380 (which is on the other side or left side in this case),which is defined as angle G.

In accordance with one of the features of the invention, thecircumferential width or section angle H falls in a range of 34° to 38°,the section angle J falls in a range of 34° to 38°, the section angle Lfalls in a range of 34° to 38°, the section angle N falls in a range of43° to 47°, the transition angle I falls in a range of 2.5° to 6.5°, thetransitional angle K falls in a range of 4° to 8°, the transition angleM falls in the range of 7° to 11°, and the transition angle G falls in arange of 5.5° to 9.5°. More preferably, the circumferential width forsectional angle H is approximately 36°, the section angle J isapproximately 36°, the section angle L is approximately 36°, the sectionangle N is approximately 45°, the transitional angle I is approximately4.5°, the transition angle K is approximately 6°, the transition angle Mis approximately 9°, and the transition angle G is approximately 7.5°.Most preferably, the circumferential width or section angle H is36.000°, the section angle J is 35.933°, the section angle L is 36.000°,the section angle N is 45.000°, the transition angle I is 4.423°, thetransition angle K is 6.139°, the transition angle M is 9.000°, and thetransition angle G is 7.500°.

In more detail as to the fifth embodiment of the blade referred to as420, teeth 32 are arranged in a unique seventy-tooth design that isdivided into two copy exact sections, namely a first side 470A and asecond side 470B by axis 472. Since the blade as shown in FIGS. 11-12has a right and left copy exact side (sides 470A and 470B respectively),only the right side will be described below (except where necessary torefer to the left side). The first side 470A includes thirty-five teeth,namely teeth 432A, 432B, 432C, 432D, 432E, 432F, 432G, 432H, 432I, 432J,434K, 432L, 432M, 432N, 432O, 432P, 432Q, 432R, 432S, 432T, 432U, 432V,432W, 432X, 432Y, 432Z, 432 a, 432 b, 432 c, 432 d, 432 e, 432 f, 432 g,432 h, and 432 i.

As with the previous embodiments and in accordance with one of thefeatures of the invention, the thirty-five teeth 432A, 432B, 432C, 432D,432E, 432F, 432G, 432H, 432I, 432J, 434K, 432L, 432M, 432N, 432O, 432P,432Q, 432R, 432S, 432T, 432U, 432V, 432W, 432X, 432Y, 432Z, 432 a, 432b, 432 c, 432 d, 432 e, 432 f, 432 g, 432 h, and 432 i of each side 470Aand 470B are not identical in size and spacing. Specifically in theembodiment shown, first side 470A is divided into four sections 480,482, 484 and 486 (and thus saw blade 420 has eight sections) of varyingcircumferential distance with differing number of teeth and size ofteeth in each. Section 480 includes cutting edges 44 of twelve teeth,namely teeth 432A, 432B, 432C, 432D, 432E, 432F, 432G, 432H, 432I, 432J,434K and 432L. Section 480 also includes the trailing components ofeleven teeth, namely teeth 432B, 432C, 432D, 432E, 432F, 432G, 432H,432I, 432J, 434K and 432L, so that those eleven teeth are fully withinsection 480. As noted above, the trailing components include land 42including tapered sections 48 and 50, and optional additional cuttingedge 52. Thereafter, section 482 includes cutting edges 44 of eightteeth, namely teeth 432M, 432N, 432O, 432P, 432Q, 432R, 432S, 432T.Section 482 also includes the trailing components of seven teeth, namelyteeth 432N, 432O, 432P, 432Q, 432R, 432S and 432T, so that those seventeeth are fully within section 482. Further thereafter, section 484includes cutting edges 44 of twelve teeth, namely teeth 432U, 432V,432W, 432X, 432Y, 432Z, 432 a, 432 b, 432 c, 432 d, 432 e and 432 f.Section 484 also includes the trailing components of eleven teeth,namely teeth 432V, 432W, 432X, 432Y, 432Z, 432 a, 432 b, 432 c, 432 d,432 e and 432 f, so that those eleven teeth are fully within section484. Finally thereafter, section 486 includes cutting edges 44 of threeteeth, namely teeth 432 g, 432 h, and 432 i. Section 486 also includesthe trailing components of two teeth, namely teeth 432 h and 432 i, sothat those two teeth are fully within section 486.

As with the previous embodiments, each of sections 480, 482, 484 and 486is specifically measured as the circumferential width from the firstcutting edge 44 of a section to the last cutting edge 44 in the samesection. Specifically, section 480 is the circumferential width from thefirst cutting edge 44 of tooth 432A of section 480 to the last cuttingedge 44 of tooth 432L in the same section 480, which is defined as angleQ. Section 482 is the circumferential width from the first cutting edge44 of tooth 432M of section 482 to the last cutting edge 44 of tooth432T in the same section 482, which is defined as angle S. Section 484is the circumferential width from the first cutting edge 44 of tooth432U of section 484 to the last cutting edge 44 of tooth 432 f in thesame section 484, which is defined as angle U. Section 486 is thecircumferential width from the first cutting edge 44 of tooth 432 g ofsection 486 to the last cutting edge 44 of tooth 432 i in the samesection 486, which is defined as angle O.

In between each of the sections are transitions or circumferentialspaces 490, 492, 494 and 496. Specifically, transition 490 is the spacebetween sections 480 and 482, transition 492 is the space betweensections 482 and 484, transition 494 is the space between sections 484and 486, and transition 496 is the space between sections 486 and 480 ofthe next side (the left side). This space is defined as thecircumferential width from the last cutting edge 44 of a section to thefirst cutting edge 44 in the next section. Specifically, transition 490is the circumferential width from the last cutting edge 44 of tooth 432Lof section 480 to the first cutting edge 44 of tooth 432M in the nextsection 482, which is defined as angle R. Transition 492 is thecircumferential width from the last cutting edge 44 of tooth 432T ofsection 482 to the first cutting edge 44 of tooth 432U in the nextsection 484, which is defined as angle T. Transition 494 is thecircumferential width from the last cutting edge 44 of the tooth 432 fof section 484 to the first cutting edge 44 of tooth 432 g in the nextsection 486, which is defined as angle V. Transition 496 is thecircumferential width from the last cutting edge 44 of the tooth 432 iof section 486 to the first cutting edge 44 of tooth 432A in the nextsection 480 (which is on the other side or left side in this case),which is defined as angle P.

In accordance with one of the features of the invention, thecircumferential width or section angle Q falls in a range of 36.5° to40.5°, the section angle S falls in a range of 30.5° to 34.5°, thesection angle U falls in a range of 64° to 68°, the section angle Ofalls in a range of 19.5° to 23.5°, the transition angle R falls in arange of 1.5° to 5.5°, the transition angle T falls in a range of 2.5°to 6.5°, the transition angle V falls in a range of 4° to 8°, and thetransition angle P falls in a range of 5.5° to 9.5°. More preferably,circumferential width for section angle Q is approximately 38.5°, thesection angle S is approximately 32.5°, the section angle U isapproximately 66°, the section angle O is approximately 21.5°, thetransition angle R is approximately 3.5°, the transitional angle T isapproximately 4.5°, the transition angle V is approximately 6°, andtransition angle P is approximately 7.5°. Most preferably, thecircumferential width or section angle Q is 38.501°, the section angle Sis 32.500°, the section angle U is 66.001°, the section angle O is21.548°, the transition angle R is 3.499°, the transition angle T is4.500°, the transition angle V is 6.000°, and the transition angle P is7.452°.

Accordingly, the improved saw blade of the above embodiments issimplified, provides an effective, safe, inexpensive, and efficientdevice which achieves all the enumerated objectives, provides foreliminating difficulties encountered with prior devices, and solvesproblems and obtains new results in the art.

In the foregoing description, certain terms have been used for brevity,clearness and understanding; but no unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art, because suchterms are used for descriptive purposes and are intended to be broadlyconstrued.

Moreover, the description and illustration of the invention is by way ofexample, and the scope of the invention is not limited to the exactdetails shown or described.

Having now described the features, discoveries and principles of theinvention, the manner in which the improved saw blade is constructed andused, the characteristics of the construction, and the advantageous, newand useful results obtained; the new and useful structures, devices,elements, arrangements, parts and combinations, are set forth in theappended claims.

1. A saw blade comprising: a flat circular disc having a peripheralouter edge; a center hole formed in the disc; a plurality ofcircumferentially spaced teeth projecting radially outwardly from theperipheral outer edge; a cutting edge on each of the teeth; a firstgroup of the cutting edges; a first circumferential width definedbetween each adjacent pair of the cutting edges in the first group; asecond group of the cutting edges; a second circumferential widthdefined between each adjacent pair of the cutting edges in the secondgroup and differing from the first circumferential width; a third groupof the cutting edges; a third circumferential width defined between eachadjacent pair of the cutting edges in the third group and differing fromthe first and second circumferential widths; a fourth group of thecutting edges; and a fourth circumferential width defined between eachadjacent pair of the cutting edges in the fourth group and differingfrom the first, second and third circumferential widths.
 2. The sawblade of claim 1 further comprising a first group circumferential widthdefined between a first of the cutting edges in the first group and alast of the cutting edges in the first group and ranging from 36.5° to40.5°.
 3. The saw blade of claim 2 further comprising a second groupcircumferential width defined between a first of the cutting edges inthe second group and a last of the cutting edges in the second group andranging from 30.5° to 34.5°.
 4. The saw blade of claim 3 furthercomprising a third group circumferential width defined between a firstof the cutting edges in the third group and a last of the cutting edgesin the third group and ranging from 64° to 68°.
 5. The saw blade ofclaim 4 further comprising a fourth group circumferential width definedbetween a first of the cutting edges in the fourth group and a last ofthe cutting edges in the fourth group and ranging from 19.5° to 23.5°.6. The saw blade of claim 2 further comprising a second groupcircumferential width defined between a first of the cutting edges inthe second group and a last of the cutting edges in the second group andranging from 64° to 68°.
 7. The saw blade of claim 2 further comprisinga second group circumferential width defined between a first of thecutting edges in the second group and a last of the cutting edges in thesecond group and ranging from 19.5° to 23.5°.
 8. The saw blade of claim1 further comprising a first group circumferential width defined betweena first of the cutting edges in the first group and a last of thecutting edges in the first group and ranging from 30.5° to 34.5°.
 9. Thesaw blade of claim 8 further comprising a second group circumferentialwidth defined between a first of the cutting edges in the second groupand a last of the cutting edges in the second group and ranging from 64°to 68°.
 10. The saw blade of claim 9 further comprising a third groupcircumferential width defined between a first of the cutting edges inthe third group and a last of the cutting edges in the third group andranging from 19.5° to 23.5°.
 11. The saw blade of claim 8 furthercomprising a second group circumferential width defined between a firstof the cutting edges in the second group and a last of the cutting edgesin the second group and ranging from 19.5° to 23.5°.
 12. The saw bladeof claim 1 further comprising a first group circumferential widthdefined between a first of the cutting edges in the first group and alast of the cutting edges in the first group and ranging from 64° to68°.
 13. The saw blade of claim 1 wherein the first group comprisesthree of the cutting edges.
 14. The saw blade of claim 13 wherein thesecond group comprises three of the cutting edges.
 15. The saw blade ofclaim 13 wherein the first group comprises twelve of the cutting edges.16. The saw blade of claim 15 wherein the second group comprises eightof the cutting edges.
 17. The saw blade of claim 16 wherein the thirdgroup comprises twelve of the cutting edges.
 18. The saw blade of claim13 wherein the first group comprises eight of the cutting edges.
 19. Thesaw blade of claim 1 wherein the number of cutting edges in the firstgroup is different from the number of cutting edges in the second group.20. The saw blade of claim 19 wherein the number of cutting edges in thefirst group is different from the number of cutting edges in the thirdgroup.
 21. The saw blade of claim 20 wherein the number of cutting edgesin the second group is different from the number of cutting edges in thethird group.
 22. The saw blade of claim 21 wherein the number of cuttingedges in the first group is the same as the number of cutting edges inthe fourth group.
 23. The saw blade of claim 20 wherein the number ofcutting edges in the second group is the same as the number of cuttingedges in the third group.
 24. The saw blade of claim 20 wherein thenumber of cutting edges in the first group is the same as the number ofcutting edges in the fourth group.
 25. The saw blade of claim 19 whereinthe number of cutting edges in the first group is the same as the numberof cutting edges in the third group.